Systems and methods for providing for the processing of objects in vehicles

ABSTRACT

An object processing system within a trailer for a tracker trailer is discloses. The object processing system includes an input area of the trailer at which objects to be processed may be presented, a perception system for providing perception data regarding objects to be processed, and a primary transport system for providing transport of each object in one of at least two primary transport directions within the trailer based on the perception data.

PRIORITY

The present application is a continuation of U.S. patent applicationSer. No. 17/086,645, filed Nov. 2, 2020, which is a continuation of U.S.patent application Ser. No. 15/833,194, filed Dec. 6, 2017, now U.S.Pat. No. 10,875,057, issued Dec. 29, 2020, which claims priority to U.S.Provisional Patent Application Ser. No. 62/430,664 filed Dec. 6, 2016,the disclosures of which are hereby incorporated by reference in theirentireties.

BACKGROUND

The invention generally relates to automated, robotic and other objectprocessing systems such as sortation systems, and relates in particularto automated and robotic systems intended for use in environmentsrequiring, for example, that a variety of objects (e.g., parcels,packages, and articles etc.) be processed and distributed to severaloutput destinations within a confined space.

Many parcel distribution systems receive parcels from a vehicle, such asa trailer of a tractor trailer. The parcels are unloaded and deliveredto a processing station in a disorganized stream that may be provided asindividual parcels or parcels aggregated in groups such as in bags, andmay be provided to any of several different conveyances, such as aconveyor, a pallet, a Gaylord, or a bin. Each parcel must then bedistributed to the correct destination container, as determined byidentification information associated with the parcel, which is commonlydetermined by a label printed on the parcel or on a sticker applied tothe parcel. The destination container may take many forms, such as a bagor a bin.

The sortation of such parcels from the vehicle has traditionally beendone, at least in part, by human workers that scan the parcels, e.g.,with a hand-held barcode scanner, and then place the parcels at assignedlocations. For example, many order fulfillment operations achieve highefficiency by employing a process called wave picking. In wave picking,orders are picked from warehouse shelves and placed at locations (e.g.,into bins) containing multiple orders that are sorted downstream. At thesorting stage individual articles are identified, and multi-articleorders are consolidated, for example into a single bin or shelflocation, so that they may be packed and then shipped to customers. Theprocess of sorting these objects has traditionally been done by hand. Ahuman sorter picks an object from an incoming bin, finds a barcode onthe object, scans the barcode with a handheld barcode scanner,determines from the scanned barcode the appropriate bin or shelflocation for the object, and then places the object in the so-determinedbin or shelf location where all objects for that order have been definedto belong. Automated systems for order fulfillment have also beenproposed. See for example, U.S. Patent Application Publication No.2014/0244026, which discloses the use of a robotic arm together with anarcuate structure that is movable to within reach of the robotic arm.

Other ways of identifying items by code scanning either require manualprocessing, or require that the code location be controlled orconstrained so that a fixed or robot-held code scanner (e.g., barcodescanner) can reliably detect it. Manually operated barcode scanners aregenerally either fixed or handheld systems. With fixed systems, such asthose used at point-of-sale systems, the operator holds the object andplaces it in front of the scanner so that the barcode faces the scanningdevice's sensors, and the scanner, which scans continuously, decodes anybarcodes that it can detect. If the object is not immediately detected,the person holding the object typically needs to vary the position orrotation of the object in front of the fixed scanner, so as to make thebarcode more visible to the scanner. For handheld systems, the personoperating the scanner looks for the barcode on the object, and thenholds the scanner so that the object's barcode is visible to thescanner, and then presses a button on the handheld scanner to initiate ascan of the barcode.

Additionally, current distribution center sorting systems generallyassume an inflexible sequence of operations whereby a disorganizedstream of input objects is first singulated by human workers into asingle stream of isolated objects presented one at a time to a humanworker with a scanner that identifies the object. The objects are thenloaded onto a conveyor, and the conveyor then transports the objects tothe desired destination, which may be a bin, a chute, a bag or adestination conveyor.

In conventional parcel sortation systems, human workers typicallyretrieve parcels in an arrival order, and sort each parcel or objectinto a collection bin based on a set of given heuristics. For instance,all objects of like type might be routed to a collection bin, or allobjects in a single customer order might be routed to a particularcollection bin, or all objects destined for the same shippingdestination, etc. may be routed to a particular collection bin. Thehuman workers or automated routing systems are required to receiveobjects and to move each to their assigned collection bin. If the numberof different types of input (received) objects is large, a large numberof collection bins is required.

Such a system has inherent inefficiencies as well as inflexibilitiessince the desired goal is to match incoming objects to assignedcollection bins. Such systems may require a large number of collectionbins (and therefore a large amount of physical space, large capitalcosts, and large operating costs) in part, because sorting all objectsto all destinations at once is not always most efficient.

Current state-of-the-art sortation systems rely on human labor to someextent. Most solutions rely on a worker that is performing sortation, byscanning an object from an induction area (chute, table, etc.) andplacing the object in a staging location, conveyor, or collection bin.When a bin is full, another worker empties the bin into a bag, box, orother container, and sends that container on to the next processingstep. Such a system has limits on throughput (i.e., how fast can humanworkers sort to or empty bins in this fashion) and on the number ofdiverts (i.e., for a given bin size, only so many bins may be arrangedto be within efficient reach of human workers).

Other partially automated sortation systems involve the use ofrecirculating conveyors and tilt trays, where the tilt trays receiveobjects by human sortation, and each tilt tray moves past a scanner.Each object is then scanned and moved to a pre-defined location assignedto the object. The tray then tilts to drop the object into the location.Other systems that include tilt trays may involve scanning an object(e.g., using a tunnel scanner), dropping the object into a tilt tray,associating the object with the specific tilt tray using a knownlocation or position, for example, a using beam breaks, and then causingthe tilt tray to drop the object when it is at the desired location.

Further, partially automated systems, such as the bomb-bay stylerecirculating conveyor, involve having trays open doors on the bottom ofeach tray at the time that the tray is positioned over a predefinedchute, and the object is then dropped from the tray into the chute.Again, the objects are scanned while in the tray, which assumes that anyidentifying code is visible to the scanner.

Such partially automated systems are lacking in key areas. As noted,these conveyors have discrete trays that can be loaded with an object;the trays then pass through scan tunnels that scan the object andassociate it with the tray in which it is riding. When the tray passesthe correct bin, a trigger mechanism causes the tray to dump the objectinto the bin. A drawback with such systems however, is that every divertrequires an actuator, which increases the mechanical complexity and thecost per divert can be very high.

An alternative is to use human labor to increase the number of diverts,or collection bins, available in the system. This decreases systeminstallation costs, but increases the operating costs. Multiple cellsmay then work in parallel, effectively multiplying throughput linearlywhile keeping the number of expensive automated diverts at a minimum.Such diverts do not ID an object and cannot divert it to a particularspot, but rather they work with beam breaks or other sensors to seek toensure that indiscriminate bunches of objects get appropriatelydiverted. The lower cost of such diverts coupled with the low number ofdiverts keep the overall system divert cost low.

Unfortunately, these systems don't address the limitations to totalnumber of system bins. The system is simply diverting an equal share ofthe total objects to each parallel manual cell. Thus each parallelsortation cell must have all the same collection bins designations;otherwise an object might be delivered to a cell that does not have abin to which that object is mapped. There remains a need for a moreefficient and more cost effective object sortation system that sortsobjects of a variety of sizes and weights into appropriate collectionbins or trays of fixed sizes, yet is efficient in handling objects ofsuch varying sizes and weights.

Further, such systems do not adequately account for the overall processin which objects are first delivered to and provided at a processingstation by a vehicle such as a trailer of a tractor trailer.Additionally, many processing stations, such as sorting stations forsorting parcels, are at times, at or near full capacity in terms ofavailable floor space and sortation resources.

SUMMARY

In accordance with an embodiment, the invention provides an objectprocessing system within a trailer for a tractor trailer. The objectprocessing system includes an input area of the trailer at which objectsto be processed may be presented, a perception system for providingperception data regarding objects to be processed, and a primarytransport system for providing transport of each object in one of atleast two primary transport directions within the trailer based on theperception data.

In accordance with another embodiment, the invention provides a systemfor providing processing of objects within a trailer for a tractortrailer. The system includes an input area within the trailer forreceiving objects to be processed, a singulation system within thetrailer for providing a singulated stream or objects within the trailer,and a perception system for receiving the singulated stream of objectswithin the trailer, and for generating perception data for facilitatingthe processing of the objects within the trailer.

In accordance with another embodiment, the invention provides a methodof providing processing of objects within a trailer for a-tractortrailer. The method includes the steps of: providing perception dataregarding an object, transporting of the object in one of at least twoprimary directions based on the perception data, and transporting theobject from the one of at least two primary directions into one of atleast two secondary directions based on the perception data.

In accordance with a further embodiment, the invention provides a methodof providing processing of objects within a trailer of a tractortrailer. The method includes the steps of: providing a singulated streamof objects within the trailer, providing perception data regarding anobject, and transporting of the object in one of at least two primarydirections within the trailer based on the perception data.

BRIEF DESCRIPTION OF THE DRAWINGS

The following description may be further understood with reference tothe accompanying drawings in which:

FIG. 1 shows an illustrative diagrammatic side view of a system inaccordance with an embodiment of the present invention, with a side wallof a trailer removed;

FIG. 2 shows an illustrative diagrammatic top view of the system of FIG.1 with the top of the trailer removed;

FIGS. 3A and 3B show illustrative diagrammatic top views of portions ofthe singulation system of the system of FIGS. 1 and 2;

FIG. 4 shows an illustrative diagrammatic side view of a system inaccordance with another embodiment of the present invention, with theside wall of the trailer removed;

FIG. 5 shows an illustrative diagrammatic top view of the system of FIG.4 with the top of the trailer removed;

FIGS. 6A and 6B show illustrative diagrammatic views of portions of thepick and drop system of the system of FIGS. 4 and 5;

FIG. 7 shows an illustrative diagrammatic front view of the drop scannersystem of FIGS. 1, 2, 4 and 5;

FIG. 8 shows an illustrative diagrammatic rear view of the drop scannersystem of FIG. 7;

FIGS. 9A and 9B show illustrative diagrammatic views of a shuttle systemof the system of FIGS. 1, 2, 4 and 5, wherein a carriage moves betweenbins (FIG. 9A), and drops an object into a bin (FIG. 9B);

FIGS. 10A and 10B show illustrative diagrammatic side views of a dropcarrier of the systems of FIGS. 1, 2, 4 and 5, wherein the drop carriermoves an object (FIG. 10A) and drops an object onto an output conveyor(FIG. 10B);

FIGS. 11A-11D show illustrative diagrammatic side views of a bagging andlabelling system of the systems of FIGS. 1, 2, 4 and 5;

FIGS. 12A-12F show illustrative diagrammatic end views of the baggingand labelling system of FIGS. 1, 2, 4 and 5;

FIG. 13 shows an illustrative diagrammatic view of a flowchart showingselected processing steps in a system in accordance with an embodimentof the present invention; and

FIG. 14 shows an illustrative diagrammatic view of a flowchart showingbin assignment and management steps in a system in accordance with anembodiment of the present invention.

The drawings are shown for illustrative purposes only.

DETAILED DESCRIPTION

In accordance with an embodiment, the invention provides a processing(e.g., sortation) system within a trailer of a tractor trailer, suchthat objects may be provided to the processing system, and processedwithin the trailer. For example, the trailer may include an input systemfor receiving a wide variety of objects to be sorted, a singulationsystem for providing a singulated stream of objects for efficientprocessing of the objects, an identification system, and routing systemfor delivering the objects to desired destinations. Generally,individual parcels need to be identified and conveyed to desiredparcel-specific locations. The described systems reliably automate theidentification and conveyance of such parcels, employing in certainembodiments, a set of conveyors and sensors and a scanning system. Inshort, applicants have discovered that when automating the sortation ofobjects, there are a few main things to consider: 1) the overall systemthroughput (parcels sorted per hour), 2) the number of diverts (i.e.,number of discrete locations to which an object can be routed), 3) thetotal area of the sortation system (square feet), 4) sort accuracy, and5) the capital and annual costs to run the system.

Sorting objects in a shipping distribution center is one application forautomatically identifying and sorting parcels. In a shippingdistribution center, parcels commonly arrive in trucks, totes, Gaylordsor other vessels for delivery, are conveyed to sortation stations wherethey are sorted according to desired destinations, aggregated in bags,and then loaded back in trucks for transport to the desireddestinations. Other applications may include the shipping department ofa retail store or order fulfillment center, which may require thatparcels be sorted for transport to different shippers, or to differentdistribution centers of a particular shipper. In a shipping ordistribution center, the parcels may take a form of plastic bags, boxes,tubes, envelopes, or any other suitable container, and in some cases mayalso include objects not in a container. In a shipping or distributioncenter the desired destination is commonly obtained by readingidentifying information printed on the parcel or on an attached label.In this scenario the destination corresponding to identifyinginformation is commonly obtained by querying the customer's informationsystem. In other scenarios the destination may be written directly onthe parcel, or may be known through other means.

In accordance with various embodiments, therefore, the inventionprovides a method of taking individual parcels from a disorganizedstream of parcels, providing a singulated stream of objects, identifyingindividual parcels, and sorting them to desired destinations, all withina confined location such as within a trailer of a tractor trailer. Theinvention further provides methods for conveying parcels from one pointto the next, for excluding inappropriate or unidentifiable parcels, forgrasping parcels, for determining grasp locations, for determining robotmotion trajectories, for transferring parcels from one conveyor toanother, for aggregating parcels and transferring to output conveyors,for digital communication within the system and with outside informationsystems, for communication with human operators and maintenance staff,and for maintaining a safe environment.

Important components of an automated object identification andprocessing system, in accordance with an embodiment of the presentinvention, are shown in FIGS. 1 and 2. FIG. 1 shows a side view of thesystem 10 within a trailer 12 (with a wall of the trailer removed forclarity), and FIG. 2 shows a top view of the system 10 (with the top ofthe trailer removed for clarity). The system 10 includes an infeedhopper 14 into which objects may be dumped, e.g., by a dumper orGaylord. An infeed cleated conveyor 16 conveys objects from the infeedhopper 12 to a primary conveyor 20. The infeed conveyor 16 may includebaffles 18 or cleats for assisting in lifting the objects from thehopper 12 onto the primary conveyor 20. A primary perception system mayinclude one or more perception units 22, 24, 26 that survey objects onthe conveyor 20, in part, to identify certain objects for returning tothe infeed hopper 14 so as to provide a singulated stream of objects. Inparticular, the system includes one or more diverters 28, 30 that may beselectively engaged to divert certain objects to return chutes 32, 34for returning to the infeed hopper 14. A portion therefore, of the inputstream is selectively adjusted by the diverters 28, 30 to provide asingulated stream of objects (as may be detected and confirmed by aperception unit 26).

The singulated stream of objects is delivered to a drop perception unit36 (as discussed below) as a singulated stream and without requiringthat a robotic system place objects into the drop perception unit. Byproviding a singulated stream of objects for processing, the system isable to more effectively control the object processing rate, andreducing the incidence of errors that may occur, for example of twoobjects in close contact with each other are perceived as being oneobject. The infeed conveyor 16 may also be in communication with acontroller 38, and the speed of the infeed conveyor 16 as well as thespeed (and even direction) of the primary conveyor 20 may be adjusted toeither slow down if moving too fast, or speed up if system determinesthat more bandwidth exists for a faster input.

Objects then drop through the drop perception unit 36 and fall onto asecondary conveyor 40, and one or more diverters 42, 44 may be employedto divert each object in a desired direction. If an object on theconveyor 40 is not diverted, then the object will fall into an unsortedcollection bin 46. When the diverter 42 is engaged to divert an objectoff of the conveyor 40, the object falls to a carriage 48 thatreciprocally runs along a track 50. The contained object in the carriage48 may then be selectively dumped onto one of a plurality of chutes 52,54, 56, 58, 60, 62 toward a respective drop container 64, 66, 68, 70,72, 74, which each include a bomb-bay style bottom drop floor as will bediscussed in more detail below. When the diverter 44 is engaged todivert an object off of the conveyor 40, the object falls to a carriage76 that reciprocally runs along a track 78. The contained object in thecarriage 76 may then be selectively dumped onto one of a plurality ofchutes 80, 82, 84, 86, 88, 90, 92, 94 toward a respective drop container96, 98, 100, 102, 104, 106, 108, 110, which each include a bomb-baystyle bottom drop floor.

When any of the drop containers 64, 66, 68 is full or otherwise completeand ready for further processing, the bottom of the ready container isdropped onto a conveyor 112 where the contents are moved toward adestination bin 114. Prior to reaching the destination bin 114 however,the contents are passed through an automatic bagging and labeling device116 as will be discussed below in more detail. When any of the dropcontainers 70, 72, 74 is full or otherwise complete and ready forfurther processing, the bottom of the ready container is dropped onto aconveyor 118 where the contents are moved through an automatic baggingand labeling device 120 toward a destination bin 122. Further, when anyof the drop containers 96, 98, 100, 102, 104, 106, 108, 110 is full orotherwise complete and ready for further processing, the contents of theready container is dropped onto a conveyor 124 where the contents aremoved through an automatic bagging and labeling device 126 toward adestination bin 128. The destination bin 114 may be accessed throughdoors 130 in the trailer, and the destination bins 120 (as well as theunsorted collection bin 46) may be accessed through doors 132 in thetrailer. The destination bin 128 (as well as the input hopper 14 and thecontroller 38) may be accessed through doors 134 at the rear of thetrailer.

FIGS. 3A and 3B show the conveyor 20 advancing objects 15 from theinfeed conveyor 16 either toward the drop scanner 36, or to beredirected via diverters to the infeed hopper 14. In particular, thesystem provides a singulated stream of objects (as shown at 17), byselectively removing certain objects (e.g., 19) by a diverter 28, 30,which move the objects 19 into a return chute 32, 34 (34 is shown) inFIG. 3A. As shown in FIG. 3A and later in FIG. 3B, this process leavesselected objects 21 in positions to provide a singulated stream ofobjects for dropping into the drop scanner 36. The speed and movement ofthe infeed conveyor 16, as well as the speed of the conveyor 20, may bemonitored and controlled to facilitate providing the singulated streamof objects for the scanner 36.

FIGS. 4 and 5 show a system 150 in accordance with another embodiment ofthe present invention. In particular, FIG. 4 shows a side view of thesystem 150 within a trailer 152 (with a wall of the trailer removed forclarity), and FIG. 5 shows a top view of the system 150 (with the top ofthe trailer removed for clarity). The system 150 includes an infeedhopper 154 into which objects may be dumped, e.g., by a dumper orGaylord. An infeed cleated conveyor 156 conveys objects from the infeedhopper 152 to a circular conveyor 158. The infeed conveyor 16 mayinclude baffles 160 or cleats for assisting in lifting the objects fromthe hopper 152 onto the circular conveyor 158. A primary perceptionsystem may include one or more perception units 162, 164 that surveyobjects on the conveyor 158, in part, to identify certain objects forselection for inclusion in a singulated stream of objects that isprovided directly to the drop perception unit 36. Objects remain on theconveyor 158 until they are selected for being grasped by an endeffector 166 of a robotic system 168, and moved by the robotic system tobe dropped into the drop perception unit 36.

Again, a singulated stream of objects are delivered to the dropperception unit 36 (as discussed below), and by providing a singulatedstream of objects for processing, the system is able to more effectivelycontrol the object processing rate, and reducing the incidence of errorsthat may occur, for example of two objects in close contact with eachother are perceived as being one object. The infeed conveyor 16 may alsobe in communication with a controller 38, and the speed of the infeedconveyor 16 as well as the speed (and even direction) of the circularconveyor 158 may be adjusted to either slow down if moving too fast, orspeed up if system determines that more bandwidth exists for a fasterinput. The remaining portions of the system 150 having referencenumerals from FIGS. 1 and 2, are the same as the portions of the system10 of FIGS. 1 and 2. Briefly, objects are identified by perception unit36, and then routed to one of carriages 48, 76, then to any of dropcontainers 64, 66, 68, 70, 72, 74, 96, 98, 100, 102, 104, 106, 108, 110,ultimately bagged and labeled (e.g., when each container is full) andprovided to one of the destination bins 114, 122, 128.

FIGS. 6A and 6B show the process of using a programmable motion system(such as robotic system) 168 having an end effector 166 that selectivelygrasps an object 121 to be processed (as shown in FIG. 6A), and movesthe object 121 to the drop scanner 36 (as shown in FIG. 6B) where theobject is dropped into the scanner 36 as shown. Other objects (e.g.,119) that are not selected for grasping and processing at that timeremain on the circulating conveyor 158. Such objects may be processed ata later date, or may be designated as not to be processed. If one ormore objects are designated as not to be processed (for whateverreason), the system may grasp the object(s) 119 and drop them into thescanner 36, not to be scanned, but simply to rout the object(s) 119 tothe unsorted collection bin 46. In this case, the system 150 would knownot to engage either of the diverters 42, 44. In each of the systems 10and 150, therefore, a singulated stream of objects is provided from thedrop scanner 36 onto the conveyor 40.

Portions of the systems 10 and 150 are described below in more detail.The perception unit 36 (which may be mounted to a side wall of thetrailer, may be supported by stands or may be suspended from above)includes a structure 170 having a top opening 172 and a bottom opening174, and the walls may be covered by an enclosing material 176 (e.g., acolored covering such as orange plastic, to protect humans frompotentially dangerously bright lights within the perception unit 36) asshown in FIGS. 7 and 8. The structure 170 includes a plurality of rowsof sources (e.g., illumination sources such as LEDs) 178 as well as aplurality of image perception units (e.g., cameras) 180. The sources 178are provided in rows, and each is directed toward the center of theopening. The perception units 180 are also generally directed toward theopening, although some cameras are directed horizontally, while othersare directed upward, and some are directed downward. The system alsoincludes an entry source (e.g., infrared source) 182 as well as an entrydetector (e.g., infrared detector) 184 for detecting when an object hasentered the perception unit 36. The LEDs and cameras therefore encirclethe inside of the structure 170, and the cameras are positioned to viewthe interior via windows that may include a glass or plastic covering(e.g., 186).

An important aspect of systems of certain embodiments of the presentinvention, is the ability to identify via barcode or other visualmarkings of objects, unique indicia associated with the object byemploying a perception system into which objects may be dropped.Automated scanning systems would be unable to see barcodes on objectsthat are presented in a way that their barcodes are not exposed orvisible. The perception system may be used in certain embodiments, witha robotic system that may include a robotic arm equipped with sensorsand computing, that when combined is assumed herein to exhibit thefollowing capabilities: (a) it is able to pick objects up from aspecified class of objects, and separate them from a stream ofheterogeneous objects, whether they are jumbled in a bin, or aresingulated on a motorized or gravity conveyor system; (b) it is able tomove the object to arbitrary places within its workspace; (c) it is ableto place objects in an outgoing bin or shelf location in its workspace;and, (d) it is able to generate a map of objects that it is able topick, represented as a candidate set of grasp points in the workcell,and as a list of polytopes enclosing the object in space.

The allowable objects are determined by the capabilities of the roboticsystem. Their size, weight and geometry are assumed to be such that therobotic system is able to pick, move and place them. These may be anykind of ordered goods, packages, parcels, or other articles that benefitfrom automated sorting. Each object is associated with unique indiciasuch as a unique code (e.g., barcode) or a unique destination (e.g.,address) of the object.

The manner in which inbound objects arrive may be for example, in one oftwo configurations: (a) inbound objects arrive piled in bins ofheterogeneous objects; or (b) inbound articles arrive by a movingconveyor. The collection of objects includes some that have exposed barcodes and other objects that do not have exposed bar codes. The roboticsystem is assumed to be able to pick items from the bin or conveyor. Thestream of inbound objects is the sequence of objects as they areunloaded either from the bin or the conveyor.

The manner in which outbound objects are organized is such that objectsare placed in a bin, shelf location or container, into which all objectscorresponding to a given order are consolidated. These outbounddestinations may be arranged in vertical arrays, horizontal arrays,grids, or some other regular or irregular manner, but which arrangementis known to the system. The robotic pick and place system is assumed tobe able to place objects into all of the outbound destinations, and thecorrect outbound destination is determined from unique identifyingindicia (identify or destination, such as a bar code or a uniqueaddress), which identifies the object or it's destination.

It is assumed that the objects are marked in one or more places on theirexterior with a visually distinctive mark such as a barcode orradio-frequency identification (RFID) tag so that they may be identifiedwith a scanner. The type of marking depends on the type of scanningsystem used, but may include 1D or 2D barcode symbologies. Multiplesymbologies or labeling approaches may be employed. The types ofscanners employed are assumed to be compatible with the markingapproach. The marking, either by barcode, RFID tag, or other means,encodes a symbol string, which is typically a string of letters andnumbers. The symbol string uniquely associates the object with uniqueidentifying indicia (identity or destination).

The operations of the systems described herein are coordinated by thecentral control system 38 as shown in FIGS. 2 and 5. This systemdetermines from symbol strings the unique indicia associated with anobject, as well as the outbound destination for the object. The centralcontrol system is comprised of one or more workstations or centralprocessing units (CPUs). The correspondence between unique identifyingindicia and outbound destinations is maintained by the central controlsystem in a database called a manifest. The central control systemmaintains the manifest by communicating with a warehouse managementsystem (WMS).

During operation, the broad flow of work may be generally as follows.First, the system is equipped with a manifest that provides the outbounddestination for each inbound object. Next, the system waits for inboundobjects to arrive either in a bin or on a conveyor. The robotic systemmay pick one item at a time from the input bin, and may drop each iteminto the perception system discussed above. If the perception systemsuccessfully recognizes a marking on the object, then the object is thenidentified and forwarded to a sorting station or other processingstation. If the object is not identified, the robotic system may eitherreplace the object back onto the input conveyor and try again, or theconveyor may divert the object to a human sortation bin to be reviewedby a human.

The sequence of locations and orientations of the perception units 36are chosen so as to minimize the average or maximum amount of time thatscanning takes. Again, if the object cannot be identified, the objectmay be transferred to a special outbound destination for unidentifiedobjects, or it may be returned to the inbound stream. This entireprocedure operates in a loop until all of the objects in the inbound setare depleted. The objects in the inbound stream are automaticallyidentified, sorted, and routed to outbound destinations.

In accordance with an embodiment therefore, the invention provides asystem for sorting objects that arrive inbound bins and that need to beplaced into a shelf of outbound bins, where sorting is to be based on aunique identifier symbol. Key specializations in this embodiment are thespecific design of the perception system so as to maximize theprobability of a successful scan, while simultaneously minimizing theaverage scan time. The probability of a successful scan and the averagescan time make up key performance characteristics. These key performancecharacteristics are determined by the configuration and properties ofthe perception system, as well as the object set and how they aremarked.

The two key performance characteristics may be optimized for a givenitem set and method of barcode labeling. Parameters of the optimizationfor a barcode system include how many barcode scanners, where and inwhat orientation to place them, and what sensor resolutions and fieldsof view for the scanners to use. Optimization can be done through trialand error, or by simulation with models of the object.

Optimization through simulation employs a barcode scanner performancemodel. A barcode scanner performance model is the range of positions,orientations and barcode element size that a barcode symbol can bedetected and decoded by the barcode scanner, where the barcode elementsize is the size of the smallest feature on the barcode. These aretypically rated at a minimum and maximum range, a maximum skew angle, amaximum pitch angle, and a minimum and maximum tilt angle.

Typical performance for camera-based barcode scanners are that they areable to detect barcode symbols within some range of distances as long asboth pitch and skew of the plane of the symbol are within the range ofplus or minus 45 degrees, while the tilt of the symbol can be arbitrary(between 0 and 360 degrees). The barcode scanner performance modelpredicts whether a given barcode symbol in a given position andorientation will be detected.

The barcode scanner performance model is coupled with a model of wherebarcodes would expect to be positioned and oriented. A barcode symbolpose model is the range of all positions and orientations, in otherwords poses, in which a barcode symbol will expect to be found. For thescanner, the barcode symbol pose model is itself a combination of anarticle gripping model, which predicts how objects will be held by therobotic system, as well as a barcode-item appearance model, whichdescribes the possible placements of the barcode symbol on the object.For the scanner, the barcode symbol pose model is itself a combinationof the barcode-item appearance model, as well as an inbound-object posemodel, which models the distribution of poses over which inboundarticles are presented to the scanner. These models may be constructedempirically, modeled using an analytical model, or approximate modelsmay be employed using simple sphere models for objects and a uniformdistribution over the sphere as a barcode-item appearance model.

As further shown with reference to FIGS. 9A and 9B, each shuttle section(e.g., carriage 48 on track 50 and carriage 76 on track 78) includes acarriage (labelled 200 in FIGS. 9A and 9B) that shuttles back and forthamong destination chutes 202 on track 204 (e.g., tracks 50, 78). Thecarriage 200 travels along the track 204 and carries objects to adesired destination chute, and tilts, dropping a contained object 206into the desired destination chute (as shown in FIG. 9B). Each object isassociated with unique identifying indicia (e.g., 205) that identifiesthe object with an identity or destination. The chutes (e.g., chutes 52,54, 56, 58, 60, 62, 80, 82, 84, 86, 88, 90, 92, 94 of FIGS. 1-4) lead todrop containers (e.g., drop containers 64, 66, 68, 70, 72, 74, 80, 82,84, 86, 88, 90, 92, 94 of FIGS. 1-6). The central computing and controlstation 38 (shown in FIGS. 2 and 4) communicates with other computersdistributed in the other components, and also communicates with thecustomer information system, provides a user interface, and coordinatesall processes.

With reference to FIGS. 10A and 10B, the drop containers of the systemsof FIGS. 1-6 may operate as follows. After a carriage (e.g., 48, 76,200) on a track 210 (e.g., track 50, 78) drops an object into a chute212 (e.g., chutes 52, 54, 56, 58, 60. 62, 80, 82, 84, 86, 88, 90, 92,94), the object 216 lands in a drop container (e.g., drop containers 64,66, 68, 70, 72, 74, 96, 98, 100, 102, 104, 106, 108, 110, 214). When thesystem determines that the drop container needs to be emptied, doors 220on the bottom of the drop container 214 open, and the contents (e.g.,object 216), fall to a conveyor 218 (e.g., conveyor 112, 118, 124), onwhich the contents travel toward destination bin (e.g., 114, 122, 128).

FIGS. 11A-11D show the operation of the automated bagging and labelingsystems 116, 120, 126 of FIGS. 1-4). In particular, a conveyor 252(e.g., conveyor 112, 118, 124) objects 250 (that came from a singledestination bin) toward a destination bin 254 into which bagged andlabelled objects are collected (e.g., bag 256 of objects bearing a label258). Before dropping into the destination bin 254, the objects 250 passthrough a bagging and labelling station 260 (e.g., bagging and labellingsystems 116, 122, 126 of FIGS. 1-6). As the objects 250 pass through(FIG. 11B), they encounter a plastic sheet 264, which forms a bag aroundthe objects with the assistance of an automated seal and labeling unit262, which moves down toward the objects as they pass through thestation 260. With reference to FIG. 11C, as the objects pass through thestation 260, the ends of the plastic sheet 264 are brought together andsealed by the automated seal and labeling unit 262, which presses on thecollected ends of the now formed bag, and prints and attaches a label266 on the bag 262 of objects 250. The labelled and bagged group ofobjects 250 are then dropped into the destination bin 254 as shown inFIG. 11D, and the automated seal and labeling unit 262 returns to thestarting position. The labelled bags of objects may periodically beremoved from the truck for further processing.

FIGS. 12A-12F further show front views of the process (shown in sideviews in FIGS. 11A-11D) of bagging groups of objects and sealing andlabelling the bags. In particular, the objects 250 travel along conveyor252 (FIGS. 11A and 12A), and contact the plastic sheet 264 as the unit262 is being lowered (FIGS. 11B and 12B). The edges of the plastic sheet264 are sealed by sealers 270, 272, and the top is cinched together andsealed by the sealing and labeling unit 274 (FIGS. 11C and 12C) thatseals the bag and prints the adhesive label 266 that is applied to thebag (FIGS. 11D and 12D). With reference to FIGS. 12E and 12F, a newsheet 265 is then anchored to anchors 280, 282 (e.g., adhesive anchors),and the unit 262 is raised, forming the new sheet 265 (FIG. 12F) forforming a new bag.

As shown in FIG. 13, a sortation process of the invention at a sortingstation may begin (step 300) by having a robotic system select, andgrasp a new object from the input buffer (step 302) and then identifythe new object (step 304). In certain embodiments, the system may firstidentify a new object and then select and grasp the identified object.The system then will determine whether the object is yet assigned to anycollection bin (step 306). If not, the system will determine whether anext bin is available (step 308). If no next bin is available and thesystem decides to retry the object later (step 310), the robotic systemwill return the object to the input buffer (step 312) and return to step302. If the system elects to not retry (step 310), the object is placedin a manual sorting area (step 314). Alternatively, the system can pickone of the collection bins that is in process and decide that it can beemptied to be reused for the object in hand, at which point the controlsystem can empty the collection bin or signal a human worker to do it.

If a next bin is available (and the system may permit any number of binsper station), the system will then assign the object to a next bin (step316). The system then places the object into the assigned bin (step318), and updates the number of objects in the bin (step 320). Thesystem them determines whether the bin is full (step 322) and if not,determines whether the bin is unlikely to receive a further object inthe near future (step 324). If the answer to either is yes, the systemindicates that the bin is ready for further processing (step 326).Otherwise, the system then returns to step 302 until finished.

A process of the overall control system is shown, for example, in FIG.14. The overall control system may begin (step 400) by permitting a newcollection bin at each station to be assigned to a group of objectsbased on overall system parameters (step 402) as discussed in moredetail below. The system then identifies assigned bins correlated withobjects at each station (step 404), and updates the number of objects ateach bin at each station (step 406). The system then determines thatwhen a bin is either full or the system expects that the associatedsorting station is unlikely to see another object associated with thebin, the associated sorting station robotic system will then place thecompleted bin onto an output conveyor, or signal a human worker to comeand empty the bin (step 408), and then return to step 402.

Systems of various embodiments provide numerous advantages because ofthe inherent dynamic flexibility. The flexible correspondence betweensorter outputs and destinations provides that there may be fewer sorteroutputs than destinations, so the entire system may require less space.The flexible correspondence between sorter outputs and destinations alsoprovides that the system may choose the most efficient order in which tohandle objects, in a way that varies with the particular mix of objectsand downstream demand. The system is also easily scalable, by addingsorters, and more robust since the failure of a single sorter might behandled dynamically without even stopping the system. It should bepossible for sorters to exercise discretion in the order of objects,favoring objects that need to be handled quickly, or favoring objectsfor which the given sorter may have a specialized gripper.

While the assignment of objects to destinations is fixed (e.g., eachobject has an identifier such as a label or barcode that is associatedwith an assigned destination), systems of certain embodiments may employcarriages or other containers that are not each fixed to assigneddestinations, but rather may be dynamically assigned during operation.In other words, the system assigns carriages or containers to certaindestination stations responsive to a wide variety of inputs, such asvolume of objects being moved to a single destination, the frequency ofsortation of the type of object, or even assigning the next availablecarriage or container to a destination associated with an acquiredobject.

The system provides in a specific embodiment an input system thatinterfaces to the customer's conveyors and containers, stores parcelsfor feeding into the system, and feeds those parcels into the system ata moderate and controllable rate. In one embodiment, the interface tothe customer's process takes the form of a Gaylord dumper, but manyother embodiments are possible. In one embodiment, feeding into thesystem is by an inclined cleated conveyor with overhead baffles. A keyto the efficient operation of the system is to feed parcels in at amodest controlled rate. Many options are available, including variationsin the conveyor slope and speed, the presence, size and structure ofcleats and baffles, and the use of sensors to monitor and control thefeed rate.

The system includes in a specific embodiment a primary perception systemthat monitors the stream of parcels on the primary conveyor. Wherepossible the primary perception system may identify the parcel to speedor simplify subsequent operations. For example, knowledge of the parcelson the primary conveyor may enable the system to make better choices onwhether to pick up a parcel rather than let it pass to the exceptionbin, which parcels to pick up first, or on how to allocate output bins.

Those skilled in the art will appreciate that numerous modifications andvariations may be made to the above disclosed embodiments withoutdeparting from the spirit and scope of the present invention.

What is claimed is: 1-30. (canceled)
 31. An object processing systemwithin a trailer for a tractor trailer, said object processing systemcomprising: a perception system providing perception data regarding anobject; first transporting system for transporting the object in one ofat least two primary directions based on the perception data; a secondtransporting system for transporting the object from the one of at leasttwo primary directions in one of at least two secondary directions basedon the perception data; and a plurality of drop containers, each ofwhich is adapted to receive the object transported in the one of the atleast two secondary directions in a selected drop container of theplurality of drop containers.
 32. The object processing system asclaimed in claim 31, wherein the object processing system furtherincludes a cleated conveyor for facilitating providing a singulatedstream of objects to the perception system.
 33. The object processingsystem as claimed in claim 31, wherein the second transporting systemincludes a plurality of carriages that are adapted to tip to drop theobject from the first transporting system to the second transportingsystem.
 34. The object processing system as claimed in claim 31, whereinthe two secondary directions are mutually orthogonal to the two primarydirections.
 35. The object processing system as claimed in claim 31,wherein the perception system includes a drop perception unit throughwhich the object falls.
 36. The object processing system as claimed inclaim 35, wherein the object falls from the drop perception unit ontothe first transporting system on which the object is transported in theone of at least two primary directions based on the perception data. 37.The object processing system as claimed in claim 31, wherein secondtransporting system transports the object in the one of the at least twosecondary directions using any of the plurality of reciprocatingcarriages movable on a linear track inside of the trailer.
 38. Theobject processing system as claimed in claim 31, wherein the objectprocessing system includes bagging station at which at least one objectis bagged at an output station.
 39. The object processing system asclaimed in claim 38, wherein the bagging station includes a sealer forsealing the bag.
 40. An object processing system within a trailer for atractor trailer, said object processing system comprising: a perceptionsystem for providing perception data regarding an object; a firsttransporting system for transporting the object in one of at least twoprimary directions based on the perception data; a second transportingsystem for transporting the object from the one of at least two primarydirections in one of at least two secondary directions based on theperception data, each of the two secondary directions being mutuallyorthogonal to the two primary directions; and at least one outputconveyor within the trailer, the at least one output conveyor beingpositioned to receive the object from the second transporting system viaa drop channel.
 41. The object processing system as claimed in claim 40,wherein the drop channel includes a drop container.
 42. The objectprocessing system as claimed in claim 40, wherein the object processingsystem further includes a cleated conveyor for facilitating providing asingulated stream of objects to the perception system.
 43. The objectprocessing system as claimed in claim 40, wherein the secondtransporting system includes a plurality of carriages that are adaptedto tip to drop the object from the first transporting system to thesecond transporting system.
 44. The object processing system as claimedin claim 40, wherein the two secondary directions are mutuallyorthogonal to the two primary directions.
 45. The object processingsystem as claimed in claim 40, wherein the perception system includes adrop perception unit through which the object falls.
 46. The objectprocessing system as claimed in claim 45, wherein the object falls fromthe drop perception unit onto the first transporting system on which theobject is transported in the one of at least two primary directionsbased on the perception data.
 47. The object processing system asclaimed in claim 40, wherein second transporting system transports theobject in the one of the at least two secondary directions using any ofthe plurality of reciprocating carriages movable on a linear trackinside of the trailer.
 48. The object processing system as claimed inclaim 40, wherein the object processing system includes bagging stationat which at least one object is bagged at an output station.
 49. Theobject processing system as claimed in claim 48, wherein the baggingstation includes a sealer for sealing the bag.
 50. An object processingsystem within a trailer for a tractor trailer, said object processingsystem comprising: a perception system for providing perception dataregarding an object; a first transporting system for transporting theobject in one of at least two primary directions based on the perceptiondata; a second transporting system for transporting the object from theone of at least two primary directions in one of at least two secondarydirections based on the perception data, each of the two secondarydirections being mutually orthogonal to the two primary directions; andat least one bagging station at which the object may be bagged withinthe trailer.
 51. The object processing system as claimed in claim 50,wherein the object processing system further includes at least oneoutput conveyor within the trailer, the at least one output conveyorbeing positioned to receive the object from the second transportingsystem via a drop channel and providing the object to the at least onebagging station.
 52. The object processing system as claimed in claim51, wherein the drop channel includes a drop container.
 53. The objectprocessing system as claimed in claim 50, wherein the object processingsystem further includes a cleated conveyor for facilitating providing asingulated stream of objects to the perception system.
 54. The objectprocessing system as claimed in claim 50, wherein the secondtransporting system includes a plurality of carriages that are adaptedto tip to drop the object from the first transporting system to thesecond transporting system.
 55. The object processing system as claimedin claim 50, wherein the two secondary directions are mutuallyorthogonal to the two primary directions.
 56. The object processingsystem as claimed in claim 50, wherein the perception system includes adrop perception unit through which the object falls.
 57. The objectprocessing system as claimed in claim 56, wherein the object falls fromthe drop perception unit onto the first transporting system on which theobject is transported in the one of at least two primary directionsbased on the perception data.
 58. The object processing system asclaimed in claim 50, wherein second transporting system transports theobject in the one of the at least two secondary directions using any ofthe plurality of reciprocating carriages movable on a linear trackinside of the trailer.
 59. The object processing system as claimed inclaim 50, wherein the bagging station includes a sealer for sealing thebag.